U.S. patent number 8,419,008 [Application Number 12/691,253] was granted by the patent office on 2013-04-16 for image forming apparatus.
This patent grant is currently assigned to Canon Kabushiki Kaisha. The grantee listed for this patent is Taro Ikeda, Kazuhiro Kosuga, Yuji Yamanaka. Invention is credited to Taro Ikeda, Kazuhiro Kosuga, Yuji Yamanaka.
United States Patent |
8,419,008 |
Ikeda , et al. |
April 16, 2013 |
Image forming apparatus
Abstract
Even if a sheet surface detection mechanism outputs a signal
indicating that an uppermost sheet among blown-up sheets is within
a conveyance range, if a trailing edge sheet surface sensor outputs
a signal indicating that the uppermost sheet among the blown-up
sheets is lower than the conveyance range when the conveyed
uppermost sheet passes by the trailing edge sheet surface sensor, a
lifting and lowering portion is controlled to lift the tray so that
the uppermost sheet is positioned within the conveyance range.
Inventors: |
Ikeda; Taro (Tokyo,
JP), Yamanaka; Yuji (Toride, JP), Kosuga;
Kazuhiro (Abiko, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Ikeda; Taro
Yamanaka; Yuji
Kosuga; Kazuhiro |
Tokyo
Toride
Abiko |
N/A
N/A
N/A |
JP
JP
JP |
|
|
Assignee: |
Canon Kabushiki Kaisha (Tokyo,
JP)
|
Family
ID: |
42125961 |
Appl.
No.: |
12/691,253 |
Filed: |
January 21, 2010 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20100194031 A1 |
Aug 5, 2010 |
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Foreign Application Priority Data
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Jan 30, 2009 [JP] |
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2009-020824 |
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Current U.S.
Class: |
271/31; 271/98;
271/97 |
Current CPC
Class: |
B65H
3/128 (20130101); B65H 1/14 (20130101); B65H
3/48 (20130101); B65H 7/02 (20130101); B65H
2406/323 (20130101); B65H 2511/20 (20130101); B65H
2801/06 (20130101); B65H 2405/353 (20130101); B65H
2405/15 (20130101); B65H 2511/152 (20130101); B65H
2511/152 (20130101); B65H 2220/01 (20130101); B65H
2511/20 (20130101); B65H 2220/02 (20130101); B65H
2220/11 (20130101); B65H 2511/20 (20130101); B65H
2220/01 (20130101) |
Current International
Class: |
B65H
7/02 (20060101) |
Field of
Search: |
;271/97,98,31 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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101051198 |
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Oct 2007 |
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CN |
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11-322101 |
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Nov 1999 |
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JP |
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Other References
European Search Report and European Search Opinion in counterpart
European Patent Application No. 10151591.4, mailed Jul. 16, 2012.
cited by applicant.
|
Primary Examiner: Karmis; Stefanos
Assistant Examiner: Suarez; Ernesto
Attorney, Agent or Firm: Fitzpatrick, Cella, Harper &
Scinto
Claims
What is claimed is:
1. A sheet-feeding device configured to feed sheets, the sheet
feeding device comprising: a tray configured to support a stack of
sheets; a lifting and lowering portion configured to lift and lower
the tray; a control portion configured to control the lifting and
lowering portion; an air blowing portion configured to blow air at
an end of the stack of sheets to blow upward the stack of sheets; a
suction conveyer configured to draw up and convey a top sheet blown
upward by the air blown by the air blowing portion; and a first
detection portion configured to detect the upper surface of the top
sheet blown upward by the air blown by the air blowing portion,
wherein the control portion is configured to control the lifting
and lowering portion based on an output of the first detection
portion so that the top sheet, blown upward by the air blown by the
air blowing portion, of the stack of sheets is positioned in a
conveyance range in which the suction conveyer can convey the top
sheet; and a second detection portion configured to detect the
upper surface of a trailing end portion of the stack of sheets,
wherein the second detection portion detects an upper surface of a
subsequent sheet, which is conveyed next to the top sheet, after
the top sheet is conveyed by the suction conveyer, and when the
control portion determines that the subsequent sheet is lower than
a predetermined level in which the suction conveyer can convey the
subsequent sheet, based on an output of the second detection
portion during conveyance of the top sheet by the suction conveyor,
the control portion controls the lifting and lowering portion so
that the lifting and lowering portion lifts the tray until the
upper surface of the subsequent sheet is above the predetermined
level, and when the control portion determines that the subsequent
sheet is positioned above the predetermined level based on the
output of the second detection portion and the control portion
determines that the subsequent sheet blown upward by the air blown
by the air blowing portion is lower than the conveyance range based
on an output of the first detection portion after the top sheet has
been conveyed, the control portion controls the lifting and
lowering portion so that the lifting and lowering portion lifts the
tray until the subsequent sheet is positioned in the conveyance
range.
2. A sheet-feeding device according to claim 1, further comprising
a regulation portion configured to regulate a position of the stack
of sheets by abutting the trailing edge of the sheets stacked on
the tray, wherein the second detection portion is provided on the
regulation portion.
3. A sheet-feeding device according to claim 2, wherein the second
detection portion comprises: a flag provided on the regulation
portion and configured to abut the upper surface of the sheets
stacked on the tray; and a slider configured to attach the flag to
the regulation portion to lift and lower the flag integrally with
the top sheet as it is separated and lifted from the stack of
sheets by the blown air from the air blowing portion; and a sensor
provided on the regulation portion and configured to generate a
detection signal according to a position of the flag.
4. A sheet-feeding device according to claim 1, wherein the control
portion is configured to control the lifting and lowering portion
such that when the tray is lifted based on the output from the
second detection portion, the tray is lifted by a preset amount
that is based on characteristics of the sheets.
5. A sheet-feeding device according to claim 4, wherein, while the
tray is being lifted by the preset amount, if the first detection
portion outputs a signal indicating that the top sheet has reached
the conveyance range, the control portion is configured to control
the lifting and lowering portion to stop the lifting of the
tray.
6. A sheet-feeding device according to claim 1, wherein the first
detection portion comprises: a first sheet surface sensor
configured to detect whether a position of the top sheet is lower
than the conveyance range; and a second sheet surface sensor
configured to detect whether the position of the top sheet is
higher than the conveyance range, and wherein the control portion
is configured to control the lifting and lowering portion based on
signals from the first sheet surface sensor and the second sheet
surface sensor such that the top sheet is positioned within the
conveyance range.
7. A sheet-feeding device according to claim 6, wherein the control
portion is configured to control the lifting and lowering portion
such that the tray is lifted until the top sheet reaches the
conveyance range and is drawn up and conveyed, and thereafter, if
it is determined based on a detection of the first sheet surface
sensor that the upper surface of the top sheet is too low, the
lifting and lowering portion is configured to lift the tray so that
the top sheet is positioned within the conveyance range.
8. A sheet-feeding device according to claim 1, wherein the
predetermined level of the upper surface of the trailing end
portion of the stack of sheets corresponds to a position where the
top sheet of the stack of sheets is or will be in the conveyance
range when the top sheet is separated and lifted from the stack of
sheets by the air blowing portion.
9. A sheet-feeding device according to claim 1, wherein the control
portion is configured to control the lifting and lowering portion
to lift the tray based on the output from the second detection
portion until the top sheet lifted and separated by the air blown
from the air blowing portion reaches the conveyance range, and
thereafter to stop the movement of the tray until a subsequent
sheet to be drawn up and conveyed by the suction conveyer is
detected by the second detection portion, the tray being not lifted
even if the second detection portion detects that the upper surface
of the trailing end portion of the stack of sheets is below the
predetermined level.
10. An image forming apparatus comprising a sheet-feeding device
according to claim 1.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming apparatus for
forming an image on a sheet, and more particularly, to an image
forming apparatus that blows air onto sheets so that the sheets are
separated from each other and fed through the image forming
apparatus.
2. Description of the Related Art
Conventionally, an image forming apparatus such as a printer and a
copying machine includes a sheet feeding device for feeding a sheet
one by one from a sheet-containing portion in which a plurality of
sheets are contained. As an example of the sheet feeding device, as
described in U.S. Pat. No. 5,645,274, there is a sheet feeding
device using air to separate and lift sheets, in which a plurality
of sheets are blown upwards by blowing air to an end portion of a
sheet stack supported by a lifting and lowering tray and only one
sheet at a time is suctioned onto a suction conveyer belt provided
above.
FIG. 13 illustrates an example of the conventional blown air sheet
feeding device. As illustrated in FIG. 13, a lifting and lowering
tray 12 on which a plurality of sheets S are stacked is provided in
a sheet container 11. When the sheets S are set on the tray 12,
positions of the sheets S are retained at an end (hereinafter
referred to as a leading edge) on a downstream side in a sheet
feeding direction by a leading edge regulation plate 17, and the
positions of the sheets S are retained at an end (hereinafter
referred to as a trailing edge) on an upstream side in the sheet
feeding direction by a trailing edge regulation plate 13. Further,
the positions of the sheets S are also retained at both side edges
in a direction (hereinafter referred to as a width direction)
orthogonal to the sheet feeding direction by side regulation plates
14.
A suction conveyer portion 20, which includes a suction conveyer
belt 21 for drawing up and conveying the sheet S, and an air
blowing portion 30 are provided above the sheet container 11. The
air blowing portion 30 blows the air to the end part of the sheets
S stack on the tray to blow the a plurality of sheets S upwards,
and the air blowing portion 30 separates each of the sheets S.
The air blowing portion 30 sucks air from the direction indicated
by the arrows C and blows a part of this air in the direction
indicated by the arrows D, and hence a few upper sheets among the
sheets stack on the tray 12 are blown upwards. In addition, the air
blowing portion 30 blows another part of the air in the direction
indicated by the arrows E, and hence an uppermost sheet among the
sheets lifted by blown air is separated from the others. The
uppermost sheet can thus be drawn up by the suction conveyer belt
21.
Frequently the sheet feeding device is adopted for a
high-productive machine which is capable of feeding (seventy)
A4-size or LTR-size sheets or more per minute. The tray 12 includes
a mechanism in which a drive unit (not shown) lifts and lowers the
tray 12 in a vertical direction while keeping the tray 12
substantially horizontal. FIG. 13 also shows the conveying portion
20 that is a circular conveyer belt 21 rotated by rollers 41, to be
described in more detail later.
FIG. 14 is a plan view illustrating details of the sheet container
11. The trailing edge regulation plate 13 for regulating the
trailing edge of a sheet is disposed while being movable in
parallel with the sheet feeding direction indicated by the arrow H.
The side regulation plates 14 and 16 for regulating the side edges
of a sheet are movable in the sheet width direction indicated by
the arrows V.
Thus, the trailing edge regulation plate 13 and the side regulation
plates 14 and 16 are movable, with the result that a minimum-size
sheet SS to a maximum-size sheet LS can be stacked and supported on
the tray 12. In order not to obstruct the movement of the side
regulation plates 14 and 16, the trailing edge regulation plate 13
is disposed so as to be movable only in a central part in the width
direction of the tray 12.
Here, the trailing edge regulation plate 13 is provided with a
trailing edge separating portion 18 capable of moving in the
vertical direction for regulating a position of a trailing edge
portion that is an end on the upstream side in the sheet feeding
direction of the uppermost sheet Sa. The trailing edge separating
portion 18 has protrusions 18D protruding from a regulation portion
surface 13C of the trailing edge regulation plate 13 illustrated in
FIG. 13, and for pressing the trailing edge portion of the
uppermost sheet Sa from above. A separation aid sheet 18E made of a
material having a high friction coefficient is glued to the lower
surface side of the protrusion 18D that contacts with the sheet,
for applying resistance to the upper surface of the stacked
sheets.
When the uppermost sheet Sa is fed by a length L2 corresponding to
the protruding length of the protrusion 18D as illustrated in FIG.
13, the trailing edge separating portion 18 is lowered so as to
abut the sheet Sb immediately below the uppermost sheet Sa. In this
case, because of a frictional force generated by a weight of the
trailing edge separating portion 18, it is possible to prevent the
second-from-the-top sheet Sb from being conveyed while the
uppermost sheet Sa is being conveyed, and hence occurrence of
feeding more than one sheet can be suppressed. In addition, if
there is no sheet positioned on the tray, the protrusion 18D abuts
a surface of the tray 12.
In FIG. 13, supporting portions 18A are provided on the trailing
edge separating portion 18, so as to engage with an engaging
portion 13E that is provided on the trailing edge regulation plate
13. Then, the supporting portions 18A are provided with a ball
bearing or a roller having a low surface friction resistance, and
hence the trailing edge separating portion 18 can be moved smoothly
in the directions indicated by the arrow G in FIG. 13.
Concerning the conventional sheet feeding device of such an air
feeding type, U.S. Patent Publication No. 2007/228640 describes a
sheet feeding device provided with a sheet surface detection
mechanism for controlling a position of the uppermost surface of
sheets contained in the sheet container 11.
FIGS. 15A and 15B are diagrams illustrating a structure of the
conventional sheet surface detection mechanism. As illustrated in
FIGS. 15A and 15B, the sheet surface detection mechanism 49
includes a sheet surface detection sensor flag 52, a first sheet
surface sensor 54 and a second sheet surface sensor 55 that are
turned on and off by rotation of the sheet surface detection sensor
flag 52, and a sensor flag mechanism 50. The first sheet surface
sensor 54 and the second sheet surface sensor 55 are photosensors
and are connected to a control device (not shown).
Here, the sheet surface detection sensor flag 52 is supported by a
support shaft 53 so that the sheet surface detection sensor flag 52
is capable of swinging.
Further, the sheet surface detection sensor flag 52 is provided
with a first detection portion 52B for shielding a light receiving
portion of the first sheet surface sensor 54, a second detection
portion 52C for shielding a light receiving portion of the second
sheet surface sensor 55, and a supporting portion 52D for
supporting, in a rotatable manner, the sheet surface detection
member 61 to be described later. The mechanism of the sheet surface
detection sensor flag 52 is shown in larger detail in FIG. 15B.
The sensor flag mechanism 50 includes a supporting member 60 having
an end 60a that is retained in a rotatable manner inside a suction
duct 22, and a sheet surface detection member 61 that is supported
at a first end by a rotation end 60b of the supporting member 60
and at a second end by a supporting portion 52D of the sheet
surface detection sensor flag 52.
The sheet surface detection member 61 is disposed below a
suctioning and conveying region of the suction conveyer portion 20,
in parallel to the sheets S stacked on the tray 12, and in a
movable manner in the vertical direction. A distance between the
upper surface of the uppermost sheet Sa that is lifted while
lifting the sheet surface detection member 61 and a belt surface of
a suction conveyer belt 21 is S1. In addition, the supporting
member that is supported in a rotatable manner inside the suction
duct 22 protrudes from retraction holes 51H1, 51H2 formed in a gap
between a plurality of suction conveyer belts 21 in the sheet width
direction to the lower side of the suctioning and conveying region
of the suction conveyer belt 21 as illustrated in FIGS. 16A and
16B. FIGS. 16A and 16B are views from underneath the suction
conveyer belt 21.
The supporting member 60, the sheet surface detection sensor flag
52, and the sheet surface detection member 61 are disposed in a
line as shown in FIG. 16B. Thus, even if the sheet abuts any
position in the longitudinal direction of the sheet surface
detection member 61, the sheet surface detection member 61 is
capable of moving vertically while keeping its parallel posture
(horizontal posture) and swinging the sheet surface detection
sensor flag 52.
Next, a sheet surface control operation based on detection by the
sheet surface detection mechanism 49 having the above-mentioned
structure will be described.
When the sheets contained in the sheet container are lifted by the
lifting of the tray 12, the upper surface of the uppermost sheet Sa
abuts the sheet surface detection member 61. Then, when the tray 12
is further lifted, the sheet surface detection member 61 is lifted
along with the uppermost sheet Sa. When the sheet surface detection
member 61 is lifted, the sheet surface detection sensor flag 52
swings the supporting portion 52D upward about the support shaft 53
as its centre.
After a specific amount of time (dependent on the speed of lifting
of the tray 12 and the number of sheets in the tray), as
illustrated in FIG. 17A, a distance between the upper surface of
the uppermost sheet Sa that is lifted while lifting the sheet
surface detection member 61 and a belt surface of the suction
conveyer belt 21 becomes S1. In this state, the first detection
portion 52B of the sheet surface detection sensor flag 52 shields
the first sheet surface sensor 54, while the second detection
portion 52C shields the second sheet surface sensor 55, and hence
ON signals are output. At this time, the control device stops the
tray 12 based on the ON signals from the first sheet surface sensor
54 and the second sheet surface sensor 55.
Next, when receiving a feed start signal, the control device starts
the air blow and controls the air input so that the upper portion
SA of the sheet stack is blown upwards as illustrated in FIG. 17B
and the tray 12 is lifted or lowered, thereby the uppermost sheet
Sa is blown upwards in a predetermined region.
Here, when the second detection portion 52C of the sheet surface
detection sensor flag 52 shields the second sheet surface sensor
55, the ON signal is output. Then, the position at which the second
sheet surface sensor 55 is turned on is set as a lower limit of the
air input region. If the ON signal of the second sheet surface
sensor 55 is not obtained while the first sheet surface sensor 54
is on, it is determined that the position is "too low", and the
tray 12 is lifted until the ON signal is obtained.
In addition, as illustrated in FIG. 18, when a distance between the
belt surface of the conveyer belt 21 and the upper surface of the
uppermost sheet Sa becomes smaller than SH, the shielding by the
first detection portion 52B is cancelled, and hence the first sheet
surface sensor 54 does not generate the ON signal (but rather
generates an OFF signal). This position is thus set as an upper
limit of the air input region. If the ON signal of the first sheet
surface sensor 54 is not obtained while the second sheet surface
sensor 55 is on, it is determined that the position is "too high",
and the tray 12 is lowered until the ON signal is obtained.
Such series of operations is shown in the following table.
TABLE-US-00001 TABLE 1 First sheet Second sheet Tray surface sensor
54 surface sensor 55 action ON OFF Lift ON ON Stop OFF ON Lower
Thus, by lifting and lowering the tray 12 based on the signals from
the first and the second sheet surface sensors 54 and 55, a
position of the tray 12 can be controlled to be the position where
only the uppermost sheet Sa can be separated from others and
conveyed. Thus, when the suction conveyer belt 21 draws up the
sheet, the sheets S can be separated and fed to the image forming
portion one by one. Thus, it is possible to achieve stable feeding
of sheets.
There is a case where an upward curl occurs at the end portion of
the sheets stacked on the tray 12 on the downstream side in the
sheet feeding direction. In this case too, as illustrated in FIG.
15A described above, the sheet surface detection member 61 abuts
the sheet with the curl at the end portion on the downstream side
in the sheet feeding direction. Then, the sheet surface detection
member 61 that abuts the sheet changes its position in parallel
vertically so as to rotate the sheet surface detection sensor flag
52. Therefore, the first sheet surface sensor 54 and the second
sheet surface sensor 55 are turned on and off appropriately, and
hence the above-mentioned sheet surface control is performed.
In other words, the lifting and lowering of the tray 12 is
controlled so that an appropriate level (appropriate distance
between the suction conveyer belt 21 and the upper sheet surface)
S1 is obtained at the position where the sheet surface detection
member 61 abuts the sheet. Further, the upper surface of the sheet
is controlled to be the appropriate level in this way, and hence a
gap is generated between the sheet end portion and the suction
conveyer belt 21, and hence the separation air is allowed to enter
smoothly as illustrated by the arrows in FIG. 15A. As a result, the
separation air securely separates the sheet from other sheets, and
hence the feeding more than one sheet or jamming of a sheet can be
prevented.
It is possible to dispose the sheet surface detection sensor flag
52 and the first and the second sheet surface sensors 54 and 55
outside the suctioning and conveying region of the suction conveyer
belt 21 and on the upstream side in the sheet feeding direction. In
this case too, the detection can be performed on the leading edge
side of the sheet S, and hence the feeding of the sheet S can
securely be performed. In addition, the first and the second sheet
surface sensors 54 and 55 are not disposed inside the suction duct
51 in this way, and hence it is possible to reduce a height of the
suction conveyer portion 20 so that the image forming apparatus can
be downsized in the height direction.
The suction duct 51 is provided with the holes 51H1 and 51H2 for
housing the sheet surface detection member 61 as illustrated in
FIGS. 16A and 16B described above, so as not to cause resistance
against conveying the sheet when the suction conveyer belt 21 draws
up the uppermost sheet. The hole 51H1 is formed in the suction duct
51 in parallel to the suctioning surface (to which the sheet is
drawn up) among the plurality of suction conveyer belts 21, and the
hole 51H2 is formed along a vertical wall of the suction duct 51.
Further, when the suction conveyer belt 21 draws up the uppermost
sheet, the drawn up sheet retracts the sheet surface detection
member 61 upward to be housed in the holes 51H1 and 51H2. Thus, the
sheet surface detection member 61 does not protrude downward from
the suctioning surface of the suction conveyer belt 21.
The hole 51H1 is formed in parallel with the suction conveyer belt
21, and hence the hole 51H1 is covered with the uppermost sheet
drawn up by the suction conveyer belt 21. Thus, air is not prone to
serious leaks from the hole 51H1. In addition, the hole portion
51H2 is formed in the direction orthogonal to the suctioning
surface of the suction conveyer belt 21, but when the sheet surface
detection member 61 is housed in the suction duct 51, the hole
portion 51H2 is blocked with the sheet surface detection member 61
itself, and hence air is not prone to serious leaks through this
hole 51H2 either. As a result, though the holes 51H1 and 51H2 are
formed in the suction duct 51, a suctioning force is not lowered.
Thus, a feeding failure of the sheet does not occur.
In the above-mentioned conventional sheet treating apparatus and
the image forming apparatus provided with the same, as illustrated
in FIG. 19, the sheet surface detection member 61 is housed inside
the suction duct 51 in the period while the uppermost sheet Sa is
conveyed. Further, in the period while the sheet surface detection
member 61 is housed inside the suction duct, a level of the sheet
surface of the second sheet Sb cannot be checked.
Here, the sheet surface of the second sheet Sb can only be checked
when the trailing edge of the uppermost sheet Sa conveyed by the
suction conveyer belt 21 passes by the sheet surface detection
member 61 and the sheet surface detection member 61 drops using its
weight under gravity so as to contact with the surface of the sheet
Sb.
For instance, when a sheet Sa of A4 size (having the
conveying-direction length of 210 mm) is conveyed by the suction
conveyer belt 21 and passes by the end portion on the downstream
side in the conveying direction of the sheet surface detection
member 61 (L2=10 mm in FIG. 13) and drops so as to contact with the
sheet Sb, necessary time period is as follows.
It is supposed that a sheet conveying speed of the suction conveyer
belt 21 is approximately 1,000 mm/sec. Then, the time period when
the sheet surface detection member 61 drops and contacts with the
sheet Sb is (210-10)/1,000, i.e., approximately 200 milliseconds.
In addition, if the sheet Sb is blown upwards below the appropriate
position by 1 mm, it takes approximately 20 milliseconds for the
sheet surface detection member 61 dropping by its weight to contact
with the upper surface of the sheet Sb.
In addition, if a blown-upward level of the sheet Sb is not an
appropriate level, it takes time to lift the tray so that the sheet
surface is lifted to the appropriate level. For instance, supposing
that the lifting speed of the tray is approximately 0.1 mm/sec, it
takes approximately 100 milliseconds to lift the tray to the
appropriate position.
In other words, if the blown-up level of the sheet is not
appropriate, time period necessary for checking the sheet surface
of the sheet Sb includes time until the housed state of the sheet
surface detection member 61 is cancelled, time period for the sheet
surface detection member 61 to become able to detect, and time
period until the sheet Sb is blown upwards to be the appropriate
level. In other words, to check the sheet surface of the sheet Sb
whose blown-upward level is not appropriate, it takes approximately
320 milliseconds (i.e., approximately 200
milliseconds+approximately 20 milliseconds+approximately 100
milliseconds).
Here, it is supposed that a sheet feeding device is capable of
usually feeding 120 sheets of A4 size per minute. Then, time per
sheet is approximately 500 milliseconds. However, if it takes
approximately 320 milliseconds to check the sheet surface of the
sheet Sb, productivity is lowered from approximately 120 sheets per
minute (approximately 500 milliseconds per sheet) to approximately
71 sheets per minute (approximately 820 milliseconds per sheet).
Further, the larger the length of the contained sheet, the longer
the time period of housing the sheet surface detection member 61.
Therefore, if sheets of A3 size or larger are used, the throughput
of sheets is further lowered.
SUMMARY OF THE INVENTION
Therefore, the present invention has been made in view of the
above-mentioned current situation, and it is desirable to provide
an image forming apparatus capable of feeding sheets through the
apparatus with good throughput of the sheets.
According to the present invention, there is provided a
sheet-feeding device configured to feed sheets, the sheet feeding
device comprising; a tray configured to support a stack of sheets,
a lifting and lowering portion configured to lift and lower the
tray, a control portion configured to control the lifting and
lowering portion, an air blowing portion configured to blow air at
an end of the stack of sheets to cause a top sheet of the stack of
sheets to be separated and lifted from the stack of sheets when in
use, a suction conveyer configured to draw up and convey the top
sheet separated and lifted by the air blown by the air blowing
portion, a first detection portion configured to detect the upper
surface of the top sheet, wherein the control portion is configured
to control the lifting and lowering portion based on an output by
the first detection portion so that in use, the top sheet of the
stack of sheets is positioned in a conveyance range in which the
suction conveyer can convey the current top sheet, and a second
detection portion configured to detect the upper surface of a
trailing end portion of the stack of sheets, wherein the control
portion is further configured to control the lifting and lowering
portion in response to an output of the second detection portion
such that when the second detection portion detects that the upper
surface of the stack of sheets is lower than a predetermined level
(REFERENCE LEVEL), the lifting and lowering portion is adapted to
lift the tray until the upper surface of the stack of sheets is
above the predetermined level. As a second aspect of the invention,
there is provided an image forming apparatus comprising the
sheet-feeding device.
Further features of the present invention become apparent from the
following description of exemplary embodiments with reference to
the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating a schematic structure of a printer
as an example of an image forming apparatus according to an
embodiment of the present invention.
FIG. 2 is a diagram illustrating a structure of a sheet feeding
device provided in the image forming apparatus illustrated in FIG.
1.
FIG. 3 is a control block diagram of the sheet feeding device
provided in the image forming apparatus illustrated in FIG. 1.
FIG. 4 is a first diagram illustrating a sheet feeding operation of
the sheet feeding device provided in the image forming apparatus
illustrated in FIG. 1.
FIGS. 5A and 5B are second and third diagrams illustrating the
sheet feeding operation of the sheet feeding device provided in the
image forming apparatus illustrated in FIG. 1.
FIGS. 6A and 6B are diagrams illustrating details of a tray and a
trailing edge regulation portion provided in the sheet feeding
device provided in the image forming apparatus illustrated in FIG.
1.
FIG. 7 is a diagram illustrating a structure of a sheet surface
detection mechanism provided in the sheet feeding device provided
in the image forming apparatus illustrated in FIG. 1.
FIG. 8 is a flowchart illustrating lifting and lowering control of
the tray provided in the image forming apparatus illustrated in
FIG. 1.
FIGS. 9A and 9B are diagrams illustrating states during the sheet
feeding operation of the sheet feeding device provided in the image
forming apparatus illustrated in FIG. 1.
FIGS. 10A and 10B are diagrams illustrating sheet surface control
of the sheet feeding device provided in the image forming apparatus
illustrated in FIG. 1.
FIG. 11 is a diagram illustrating a turned-off state of a trailing
edge sheet surface sensor provided in the sheet feeding device of
the image forming apparatus illustrated in FIG. 1.
FIG. 12 is a flowchart illustrating lifting and lowering control of
the tray provided in the image forming apparatus illustrated in
FIG. 1.
FIG. 13 is a diagram illustrating a structure of a sheet feeding
device provided in a conventional image forming apparatus.
FIG. 14 is a plan view illustrating detail of a sheet container of
the sheet feeding device illustrated in FIG. 13.
FIGS. 15A and 15B are a first pair of diagrams illustrating a
structure of a sheet surface detection mechanism of the sheet
feeding device illustrated in FIG. 13.
FIGS. 16A and 16B are a second pair of diagrams illustrating a
structure of the sheet surface detection mechanism of the sheet
feeding device illustrated in FIG. 13.
FIGS. 17A and 17B are first diagrams illustrating sheet surface
control operation of the sheet feeding device illustrated in FIG.
13.
FIG. 18 is a second diagram illustrating the sheet surface control
operation of the sheet feeding device illustrated in FIG. 13.
FIG. 19 is a third diagram illustrating the sheet surface control
operation of the sheet feeding device illustrated in FIG. 13.
DESCRIPTION OF THE EMBODIMENTS
Detailed description of an exemplary embodiment of the invention is
described below with reference to the drawings.
FIG. 1 is a diagram illustrating a schematic structure of a printer
as an image forming apparatus provided with a sheet feeding device
according to an embodiment of the invention.
In FIG. 1, an image scanning portion 130 is provided in an upper
portion of a printer main body 101 of the printer 100, for scanning
an original D, which is placed on a platen glass 120a as an
original-placing platen by an automatic original feeder 120.
Further, an image forming portion 102 and a sheet feeding device
103 for feeding a sheet S to the image forming portion 102 are
provided below the image scanning portion 130.
Here, the image forming portion 102 includes a photosensitive drum
112, a development device 113, and a laser scanner unit 111.
Further, the sheet feeding device 103 includes a plurality of sheet
containers 11 and suction conveyer belts 21 serving as feeding
belts. The sheets S such as OHT (overhead projector transparencies)
are contained in the sheet containers 11, and the sheet containers
11 are detachably attached to the printer main body 101. The
feeding belt is an example of a sheet feeding unit configured to
feed the sheets S contained in the sheet container 11 to the image
forming portion 102.
The image forming operation of the printer 100 having the
above-mentioned structure will be described below.
The image scanning portion 130 scans an image when a control device
(illustrated in FIG. 3 to be described later) included in the
device body 101 outputs an image scanning signal to the image
scanning portion 130. Then, a laser scanner unit 111 emits a laser
beam according to an electric signal of the scanned image to
irradiate the photosensitive drum 112. Here, the photosensitive
drum 112 is previously charged, and an electrostatic latent image
is formed by the laser beam irradiation. Then, the development
device 113 develops the electrostatic latent image to form a toner
image on the photosensitive drum 112.
Elsewhere, the sheet S is fed from the sheet container 11 when the
control device outputs a sheet feeding signal to the sheet feeding
device 103. Then, a registration roller 117 conveys the fed sheet S
to a transfer portion in synchronization with the toner image on
the photosensitive drum 112. The transfer portion is formed by the
photosensitive drum 112 and a transfer charger 118.
Next, the toner image is transferred to the sheet S conveyed to the
transfer portion, and the sheet is conveyed to a fixing portion
114. Then, the fixing portion 114 heats and pressurises the sheet S
to fix permanently the unfixed transfer image to the sheet S. A
discharge roller 116 discharges the sheet to which the image is
transferred from the printer main body 101 to the discharge tray
119. The timing of the image forming apparatus is controlled by a
control device 200.
FIG. 2 illustrates a structure of the sheet feeding device 103. In
FIG. 2, reference numerals the same as those in the above-mentioned
FIG. 13 refer to the same or corresponding parts.
The sheet container 11 includes a tray 12 that is liftable and
lowerable, a trailing edge regulation plate 13, a leading edge
regulation plate 17, and side edge regulation plates 14 which
regulate a position in the width direction orthogonal to a sheet
feeding direction of the sheets S. The position of the trailing
edge regulation plate 13 and the positions of the side edge
regulation plates 14 can be changed according to the size of the
contained sheet. In addition, the trailing edge regulation plate 13
abuts trailing edges of the sheets on the upstream side in the
sheet conveying direction, and a trailing edge separating portion
18 is provided on the trailing edge regulation plate 13. The
trailing edge separating portion 18 regulates a position of the
trailing edge portion of the uppermost sheet Sa, the trailing edge
portion being on the upstream side in the sheet feeding direction.
The trailing edge separating portion 18 is movable in the vertical
direction.
The sheet container 11 can be pulled out from a printer main body
101 along slide rails 15. When the sheet container 11 is pulled out
from the printer main body, the tray 12 is lowered to a
predetermined position so that sheets can be added or exchanged.
The tray 12 is lifted and lowered by a stepping motor or a DC servo
motor, and it is possible to lower the tray 12 by repeating a
stepping operation of alternating between moving for a
predetermined period and staying in a vertical position for a
predetermined period.
In addition, a sheet feeding mechanism (hereinafter referred to as
an air sheet feeding mechanism 150) of the air-controlled sheet
feeding system configured to separate and feed the sheets one by
one is disposed above the sheet container 11. The air sheet feeding
mechanism 150 includes a suction conveyer portion 20 which conveys
the sheet S stacked on the tray 12 while applying suction to the
sheet S and an air blowing portion 30 which blows air onto the
upper part of the sheet stack on the tray, thus separating the
sheets S one by one.
Here, the suction conveyer portion 20 includes a suction conveyer
belt 21 which is passed over the belt drive rollers 41 and which
conveys the sheet S in the right direction in FIG. 2 while applying
suction to the sheet S. The suction conveyer portion 20 also
includes a suction fan 36 which generates a negative pressure in
order to draw the sheet S up to the suction conveyer belt 21, and a
suction duct 22 which is disposed within the suction conveyer belt
21 and which is used to suck the air through the suction holes (not
shown) formed in the suction conveyer belt 21.
The suction conveyer portion 20 further includes a suction shutter
37 which is disposed between the suction fan 36 and the suction
duct 22 to turn on and off the suction operation of the suction
conveyer belt 21. In this embodiment, a plurality of suction
conveyer belts 21 are disposed at predetermined intervals in the
width direction, the width direction being orthogonal to the
conveying direction of the paper and typically corresponding to the
narrower dimension of rectangular sheets. The plurality of suction
conveyer belts 21 may therefore be aligned side-by-side.
The air blowing portion 30 includes a loosening nozzle 33 (for
"loosening" the sheets from each other) and a separation nozzle 34
(for separating the sheets from each other with a cushion of air).
The loosening nozzle 33 and the separation nozzle 34 are configured
to blow the air on an upper part of the contained sheets S. The air
blowing portion 30 further includes a separation fan 31 and a
separation duct 32, the latter of which supplies the air from the
separation fan 31 to the loosening nozzle 33 and the separation
nozzle 34.
Thus, a part of the air sucked (i.e. caused to flow) in the
direction indicated by the arrow C by the separation fan 31 passes
through the separation duct 32, and this portion of air is blown in
the direction indicated by the arrow D through the loosening nozzle
33 to lift several sheets in the upper part of the sheets S stacked
on the tray 12. The remaining air input into the air blowing
portion 30 is blown out in the direction indicated by the arrow E
through the separation nozzle 34, and this remaining air separates
the sheets lifted by the loosening nozzle 33, one by one, and lets
the suction conveyer belt 21 apply suction to a sheet to attract it
to the suction conveyer belt.
FIG. 3 is a control block diagram of the sheet feeding device. The
control device 200 is connected to a trailing edge sheet surface
sensor configured to detect a trailing edge surface of a sheet, as
well as to a first sheet surface sensor 54 and a second sheet
surface sensor 55 that are provided in a sheet surface detection
mechanism to be described later. In addition, the control device
200 is connected to a tray lifting and lowering drive motor M1
configured to lift and lower the tray 12, a suction conveyer belt
drive motor M2 configured to drive a suction conveyer belt 21, and
a shutter solenoid SL configured to rotate a suction shutter 37. In
addition, the control device 200 is connected to a suction fan 36
configured to generate negative pressure for drawing a sheet up
onto the suction conveyer belt 21, and a separation fan 31
configured to blow air to the sheet.
Next, the sheet feeding operation of the sheet feeding device 103
(the air sheet feeding mechanism 150) having the above-mentioned
structure will be described.
First, a user pulls out the sheet container 11 to set sheets S on
the tray 12. Thereafter, the user pushes in the sheet container 11
to a predetermined position as illustrated in FIG. 2. Then, a tray
lifting and lowering drive motor M1 is driven by the control device
200 illustrated in FIG. 3. Thus, as illustrated in FIG. 4, the tray
12 is lifted in the direction indicated by the arrow A. When a
distance between the suction conveyer belt 21 and the uppermost
sheet Sa is reduced to a distance B, it has reached a sheet
feed-ability position where the sheet can be fed and the control
device 200 stops the tray 12 at that position. Then, the control
device 140 is ready to detect a sheet-feeding signal for starting
the sheet feed.
Next, when the control device 200 detects the sheet-feeding signal,
the control device 200 activates the separation fan 31 to suck the
air in the direction indicated by the arrow C as illustrated in
FIG. 5A. The air passes through the separation duct 32, and the air
is blown from the loosening nozzle 33 and the separation nozzle 34
in the directions indicated by the arrows D and E, respectively, to
the sheet stack. Thereby, several sheets in the upper part of the
sheet stack are lifted and separated by the blown air. The control
device 200 also activates the suction fan 36 to output the air as
exhaust air in the direction indicated by the arrow F in FIG. 5A.
At this time, the suction shutter 37 is still closed such that air
is not blown through the conveyer belts 21, but rather, a negative
pressure is created in the space between the fan 36 and the shutter
37.
When a predetermined time has passed from the detection of the
sheet feeding signal so that lifting of the upper sheet Sa is
stabilized, the control device 200 drives the shutter solenoid SL
so that the suction shutter 37 is rotated in the direction
indicated by the arrow G as illustrated in FIG. 5B. The rotation of
the suction shutter 37 causes a passage through the shutter to
open. Thus, a suction force in the direction indicated by the arrow
H is generated through suction holes provided in the suction
conveyer belt 21. The combination of this suction force H and
separation air E from the separation nozzle 34 enables only the
uppermost sheet Sa to be drawn up onto the suction conveyer belt
21.
Then, a suction conveyer belt drive motor M2 illustrated in FIG. 3
is driven by the control device 200 and, as illustrated in FIG. 5B,
the belt drive roller 41 is rotated in the direction indicated by
the arrows J. As a result, the uppermost sheet Sa is conveyed in
the direction indicated by the arrow K in the state in which the
uppermost sheet Sa is drawn up onto the suction conveyer belt 21.
Then, the uppermost sheet Sa is conveyed toward the image forming
portion by a pair of draw rollers 42 rotated in the directions
indicated by the arrows L and M.
FIGS. 6A and 6B are diagrams illustrating details of the tray 12
and the trailing edge regulation portion 13. The trailing edge
regulation portion 13 includes a trailing edge separating portion
18. The trailing edge separating portion 18 (shown in FIG. 6B)
includes the above-mentioned protrusion 18D, a separation aid sheet
18E made of a material having a high friction coefficient, and a
slider 18F that holds the protrusion 18D and the separation aid
sheet 18E and is slidable in the direction indicated by the arrow
G. Because the slider 18F is slidable along the length of the
trailing edge regulation portion 13, the trailing edge separating
portion 18 (including the protrusion 18D and sheet 18E) can be
lifted and lowered together with the uppermost sheet so as to
follow a movement of the top surface of the uppermost sheet
securely.
In addition, as illustrated in FIG. 7, the slider 18F of the
trailing edge separating portion 18 is provided with a trailing
edge sheet surface detection sensor flag 18G. The trailing edge
sheet surface sensor 56 provided in the trailing edge regulation
portion 13 is turned on and off based on a position of the trailing
edge sheet surface detection sensor flag 18G.
As will be described later, sheets are fed one by one so that the
upper surface position of the stack of sheets is effectively
lowered because there are fewer sheets left on the tray 12. When
the upper surface position of the current uppermost sheet becomes
lower than a regulated range (i.e. when the stack decreases in
height to below a predetermined height or threshold), the trailing
edge sheet surface sensor 56 is turned off by the trailing edge
sheet surface detection sensor flag 18G that is lowered as the
upper surface position of the stack of sheets is lowered. In this
embodiment, the trailing edge regulation portion 13 is provided
with the trailing edge sheet surface sensor 56 (that is a second
sheet surface detection portion) configured to detect an upstream
part (in the sheet feeding direction) of the upper surface of the
current uppermost sheet among the sheets lifted by blown air. As a
previous uppermost sheet is conveyed away from the pile of sheets
S, the current uppermost sheet is the second sheet and is therefore
also the sheet that is being detected by the second sheet surface
detection portion 56. Therefore, sheets having different lengths in
the sheet conveying direction may be used because the top surface
of a subsequent sheet (no matter the length of the sheet) is
measured, rather than a position of a leading or trailing edge. As
all lengths of sheet have a top surface that can be detected,
different lengths of sheet may be used in the same conveying
system.
In this embodiment, as illustrated in FIG. 7, a sheet surface
detection mechanism 49 is disposed above the tray, the sheet
surface detection mechanism 49 including a sheet surface detection
sensor flag 52, a first sheet surface sensor 54, a second sheet
surface sensor 55 and a sensor flag mechanism 50. The control
device 200 of FIG. 3 described above performs the lifting and
lowering control of the tray 12 based on the turned-on and
turned-off states of the first and the second sheet surface sensors
54 and 55 and the trailing edge sheet surface sensor 56. These
three sensors are part of the sheet surface detection mechanism
that is a "first sheet surface detection portion" configured to
detect the upper surface of the uppermost sheet among the sheets
lifted by the blown air. The first sheet surface sensor 54 detects
whether the position of the uppermost sheet is lower than an
appropriate range within which the suction conveyer portion 20 can
apply suction to the sheet as described above. The second sheet
surface sensor 55 detects whether the position of the uppermost
sheet is higher than the same appropriate range. Together, the
sheet surface sensors 54 and 55 determine whether the uppermost (or
top) sheet is within the appropriate range.
Next, the lifting and lowering control of the tray 12 according to
this embodiment will be described with reference to a flowchart
illustrated in FIG. 8.
When receiving a feed start signal, the control device 200 starts
preparation for feeding. First, rotation of the separation fan 31
is started, and air blowing is started, and sheets are lifted by
the blown air. After that, based on the on/off signal from the
first sheet surface sensor 54 and the second sheet surface sensor
55, the tray lifting and lowering drive motor M1 is driven so that
the tray 12 is lifted and lowered.
Then, if the first and the second sheet surface sensors 54 and 55
are not caused to be turned on (e.g. because no signal is received)
(NO in S20), the tray 12 is lifted and lowered (S21) appropriately
as described above. If the first and the second sheet surface
sensors 54 and 55 are caused to be turned on (e.g. by receiving a
signal) (YES in S20), feeding of sheets is started (S22).
When the feeding of sheets is started, the uppermost sheet Sa is
drawn up and fed by the suction conveyer belt 21. After that, when
the uppermost sheet Sa is fed by the length of L2 (as illustrated
in FIG. 7) or more, the trailing edge separating portion 18 drops
so that a lower surface of the separation aid sheet 18E abuts a
surface of the next sheet Sb.
The uppermost sheet Sa is fed, a position of the uppermost sheet is
down so that the trailing edge sheet surface detection sensor flag
18G also drops. Soon afterward, the trailing edge sheet surface
sensor 56 stops detecting the trailing edge sheet surface detection
sensor flag 18G, and the trailing edge sheet surface sensor 56 is
turned off. In other words, when sheets are fed so that the upper
surface of the current uppermost sheet drops below a reference
level, the trailing edge sheet surface sensor 56 outputs an OFF
signal that is a detection signal indicating that the uppermost
sheet among the air-lifted sheets is below the reference level. The
trailing edge sheet surface sensor 56 determines whether the
uppermost (or top) sheet is above the reference level.
Here, the OFF signal is output as described above when the
uppermost sheet Sa passes the trailing edge separating portion 18.
On this occasion, the sheet surface detection mechanism 49 is
detecting the uppermost sheet Sa. However, in this embodiment, even
if the sheet surface detection mechanism 49 is detecting the
uppermost sheet Sa, the tray 12 is lifted when the trailing edge
sheet surface sensor 56 becomes turned off. In other words, if the
trailing edge sheet surface sensor 56 is turned on, the tray is
lifted regardless of the signal from the first sheet surface
detection portion.
Next, after the tray 12 is lifted in this way, it is determined
whether or not the trailing edge sheet surface sensor 56 is caused
to be turned on (S23). If the trailing edge sheet surface sensor 56
is not turned on (NO in S23), it is determined that the tray 12 is
"too low", and the tray 12 is lifted until an ON signal is obtained
(S24).
A distance by which the trailing edge side of the sheet can be
lifted by the blown air is restricted to some extent by the weight
of the trailing edge separating portion 18. Hence, the trailing
edge side of the sheets is lower than the leading edge side, when
the sheet is lifted by blown air. The appropriate range determined
by the detection of the sheet surface sensors 54 and 55 is
different position in a high direction from the reference level
determined by the detection of trailing edge sheet surface sensor
56. The reference level is set lower than the appropriate
range.
In this way, if the sheet is fed so that the level of the uppermost
sheet is decreased, this is detected by the trailing edge sheet
surface sensor 56 earlier than the sheet surface detection
mechanism 49. When the suction conveyer belt 21 draws up the
uppermost sheet, the drawn up sheet retracts the sheet surface
detection member 61 upward to be housed in the holes 51H1 and 51H2.
Therefore when the suction conveyer belt 21 conveys the uppermost
sheet, the sheet surface detection mechanism 49 doesn't detect the
subsequent sheet Sb. However shortly after the trailing edge
portion of the sheet passes by the trailing edge sheet surface
sensor 56, the trailing edge sheet surface sensor 56 can detect the
subsequent sheet Sb. The trailing edge sheet surface sensor 56
detects the subsequent sheet Sb earlier than the sheet surface
detection mechanism 49.
Therefore, if the lifting of the tray 12 is controlled based on the
signal from the trailing edge sheet surface sensor 56, the tray 12
can be lifted and stopped earlier without having to make subsequent
corrections, and hence throughput of the sheet feeding device is
optimised. The tray 12 is controlled and lifted based on a lift
amount that is set in advance based on information such as
thickness of the sheet when the lifting of the tray 12 is started
based on the signal from the trailing edge sheet surface sensor 56
so as to lift the tray 12.
The sheet surface detection mechanism 49 checks whether or not the
leading edge of the uppermost sheet is lifted by blown air within a
predetermined region when the suction conveyer belt 21 dose not
convey the sheet.
Therefore, if the trailing edge sheet surface sensor 56 is turned
on (YES in S23), it is determined next whether or not the uppermost
sheet position is in the appropriate range based on the signal from
the second sheet surface sensor 55. If the second sheet surface
sensor 55 is not turned on (NO in S25), the tray 12 is lifted (S26)
until the second sheet surface sensor 55 is turned on (YES in
S25).
Further, if the sheet surface on the leading edge side is out of
the predetermined region despite the ON signal being obtained from
the trailing edge sheet surface sensor 56, i.e., if the second
sheet surface sensor 55 is turned off (NO in S25), the tray 12 is
lifted (S26). However, in this case too, the tray 12 (the uppermost
sheet) is already lifted to the level that enables the trailing
edge sheet surface sensor 56 to output the ON signal, and hence it
does not take such a length of time that may affect throughput.
Next, when the second sheet surface sensor 55 is turned on (YES in
S25), the tray 12 is stopped (S27) and afterward the feeding of
sheets is started (S28). If N sheets are stacked on the tray 12,
the above-mentioned control is repeated until the N.sup.th sheet is
fed. When the N.sup.th sheet is fed (YES in S29), the feeding
operation is stopped.
Thus, in this embodiment, if the trailing edge sheet surface sensor
56 detects that the uppermost sheet is lower than the reference
level when the sheet passes, the tray 12 is controlled to be
lifted. Thus, any number and size of sheet can be fed without
reducing the throughput of the sheets.
Further, if this structure is adopted, it is sufficient that the
trailing edge sheet surface sensor 56 detects at least the state
where the uppermost sheet is "too low" when the sheets are fed
successively. Thereafter, when the uppermost sheet is no longer
"too low", the tray lifting can automatically stop. Therefore, the
structure can be simpler than one including the sheet surface
detection mechanism 49, by only including a trailing edge sheet
surface sensor 56. As a result, the trailing edge sheet surface
sensor 56 can easily be disposed inside the trailing edge
regulation portion.
In addition, in order that the uppermost sheet is positioned within
the appropriate range, it is possible to provide a plurality of
trailing edge sheet surface sensors so that the detection positions
for generating level insufficiency signals can be switched, and to
perform the sheet surface level control of the trailing edge
portion by the plurality of positions. Thus, the structures are
applicable to the case where a difference between a sheet surface
level on the leading edge side and sheet surface level on the
trailing edge side exists depending on various weights or sizes of
the sheets. Thus, it is possible to achieve a more stable state of
sheets being lifted by the blown air, and hence occurrence of
feeding more than one sheet or jamming of a sheet can be better
prevented.
A blowing state of sheet-loosening air or sheet-separation air may
change during the time within which the suction conveyer belt draws
up the uppermost sheet, or during a very short time between when
the feeding of the uppermost sheet starts and when the trailing
edge separating portion 18 abuts the surface of the next sheet.
Thus, if the blowing state changes in this way, a lifted and
separated state of the sheets on the leading edge side or the
trailing edge side is disturbed. As a result, the separation
between sheets may become insufficient, resulting in the feeding of
more than one sheet or jamming of a sheet. In addition, the lifting
and separating state of the sheets may be disturbed depending on
characteristics of the sheet, resulting in the same problem.
FIGS. 9A and 9B are diagrams illustrating a sheet that is being
lifted by the blown air and fed into the image-forming apparatus.
FIG. 9A illustrates a desired state of the sheet that is being
conveyed while FIG. 9B illustrates an undesirable state of the
sheet that is being conveyed.
In the preferable state of the sheets illustrated in FIG. 9A, the
trailing edge sheet surface sensor 56 is caused to be turned on and
the tray (not shown) is stopped. In this case, a distance between
the suction conveyer belt 21 and the leading edge side of the
uppermost sheet Sa is Z1, while a distance between the trailing
edge side of the uppermost sheet Sa and the suction conveyer belt
21 is Z2. The sheet stack SA is lifted with blown air substantially
uniformly, and hence the separation is performed appropriately. In
addition, a distance Z1 between the suction conveyer belt 21 and
the uppermost sheet Sa is steady, and hence the separation air
enters between the uppermost sheet Sa and the immediately
subsequent sheet Sb after the uppermost sheet Sa is drawn up. Thus,
the feeding out of more than one sheet can be prevented.
In the undesirable state illustrated in FIG. 9B, the position of
the trailing edge of the uppermost sheet Sa is not different from
the position in FIG. 9A. Although the distance between the suction
conveyer belt 21 and the trailing edge side of the uppermost sheet
Sa is also Z2, the distance between the leading edge side of the
uppermost sheet Sa and the suction conveyer belt 21 is Z3, which is
less than Z1. Furthermore, the uppermost sheet Sa is lifted
together with the immediately subsequent sheet Sb as a sheet
bundle. In this state, the separation between the sheets may become
insufficient so that the feeding of more than one sheet can easily
occur. Even if uniform separation of sheets can be obtained in this
state, the separation air cannot enter appropriately between sheets
because the distance Z3 on the leading edge side is too small.
Therefore, the likelihood of feeding more than one sheet might be
increased.
Such an undesirable state occurs in the case where the sheet type
is thick and has less flexibility, for example. In other words, if
the sheet is thick and has less flexibility, the difference between
Z2 and Z1 (or Z2 and Z3) is not as large as illustrated in FIGS. 9A
and 9B when the sheet is separated and lifted by the blown air. As
a result, a thin air layer is generated between sheets also on the
trailing edge side. On the other hand, because of being distant
from the leading edge side, the loosening air for sustaining the
blown-up state might not enter very far between the sheets.
Therefore, a small vibration may occur in the horizontal
direction.
In this state, the trailing edge sheet surface sensor 56 may be
turned on and off frequently. Then, despite the leading edge side
being appropriately positioned, the tray may be lifted excessively
depending on a result of the detection of the sheet surface on the
trailing edge side.
In addition, if the sheet has a thickness of approximately 0.1 mm
or less, and if the trailing edge sheet surface sensor 56 has an
error of approximately 1 mm as an accumulation of dimension errors
of components constituting the trailing edge sheet surface sensor
56, ten or more sheets may be lifted by the blown air as a sheet
bundle. It is thus very important to consider factors of the
dimensional errors of the components of the sheet lifting and
conveying system.
Further, even if the dimensional errors of the components are
controlled, a thin sheet can naturally be loosened easily due to
characteristics (i.e. low weight) of the thin sheet. If the sheets
are loosened more than initially envisioned while the sheets are
fed, the sheets may enter a state in which the trailing edge sheet
surface sensor 56 alternates between on and off irregularly. In
this case, too, unnecessary lifting of the tray may be performed
similarly to the case of the thick sheet, and its influence is even
larger than that in the case of the thick sheet. In the case of the
thin sheet, the number of sheets lifted as a sheet bundle may
increase, and the feeding of more than one sheet or jamming of a
sheet may occur.
In order to prevent the above risks, in this embodiment, when a
time limit lapses after the start of the conveyance of the sheets,
i.e., after the checking of the sheet surface position, the tray 12
is stopped. Here, FIGS. 10A and 10B illustrate a change in position
of the sheet surface on the trailing edge side of the sheet and the
signal of the trailing edge sheet surface sensor 56 in the case
where the tray 12 is stopped after a time lapse from the start of
feeding of the sheet.
FIG. 10A illustrates conventional control of the blown air while
FIG. 10B illustrates a case of the control according to this
embodiment. In the conventional control illustrated in FIG. 10A, as
a sheet-feeding operation is started so that a first sheet, a
second sheet, and then a third sheet are fed into the image-forming
apparatus, the surface of the remaining sheets is gradually lowered
toward a reference level. The sheet numbers are shown as integers 1
to 7 on FIG. 10A. When the feeding of a third sheet is finished and
the trailing edge separating portion contacts a surface of a fourth
sheet, the fourth sheet surface is lower than the reference level.
At this time, the signal from the trailing edge sheet surface
sensor 56 changes from ON to OFF, as shown in the bottom graph of
FIG. 10A. Of course, the reference level may be after any
predetermined decrease in height of the stack level (and thus after
the feeding of any number of sheets, not just three).
When the signal from the trailing edge sheet surface sensor 56
changes in this way, the lifting of the tray 12 is started so that
the fourth sheet becomes the same level as the first sheet was a
the beginning of the sheet feeding. However, because the sheet is
in a state where it is lifted from the surface of the tray by the
action of the blown air between the sheets, the sheet surface is
not lifted at the same time as the tray 12 starts to be lifted.
There is a delay between the tray being raised and the sheets that
are lifted by the blown air also being raised because of the
cushion of air between sheets being compressed. The lifting of the
tray 12 first causes a change in the air cushion thickness on the
leading edge side.
The blowing states (i.e. air pressure) of the sheet-loosening air
and the sheet-separation air change because of the change in the
air cushion thicknesses and resistance in the air flow. This causes
the sheet surface to start to be lifted after a delay time.
Therefore, even if the signal from the trailing edge sheet surface
sensor 56 changes from OFF to ON so that the tray is stopped after
that, the sheet surface continues to be lifted for a short time
depending on the air flow D, E from the air input fan 31.
This lifting of the sheet surface by the tray may cause disturbance
of the air cushion under the sheet after the trailing edge portion
of the sheet passes by the trailing edge sheet surface sensor 56.
This disturbance of the air cushion under the sheet disappears
substantially instantly, and the sheet surface is restored to being
higher than the reference level. Therefore, it is intrinsically
unnecessary to lift the tray 12 as much as it is lifted, but the
signal from the trailing edge sheet surface sensor 56 may change
from ON to OFF if the air cushion is disturbed. Then, if the signal
from the trailing edge sheet surface sensor 56 changes, the tray 12
is already raised by time of the change and has potentially gone
too high.
For instance, as illustrated in FIG. 10A, when the tray 12 is
lifted, the fourth sheet becomes the same level as that of the
first sheet and is fed into the feeding or conveying apparatus.
Then, a fifth sheet starts to be fed. At this time, if a
disturbance of the air cushion occurs twice, the signal from the
trailing edge sheet surface sensor 56 also changes twice. Then, if
such a signal change occurs twice, a deviation from an original
level of the sheet surface becomes R2 in FIG. 10A, which is higher
than the level when the feeding was started by R1 in FIG. 10A. If
the level of the sheet surface becomes too high, the feeding of
more than one sheet or other trouble may occur. Such the
disturbance in the air cushion between sheets occurs unexpectedly
depending on type or state of the sheets.
In contrast, in the present embodiment, when the conveyance of the
fourth sheet is performed, the tray 12 is stopped at the position
where the fourth sheet is lower than the first sheet so that at
least the fourth sheet can be drawn up and conveyed at the timing
when the signal from the trailing edge sheet surface sensor 56
changes to ON. In other words, after the signal from the trailing
edge sheet surface sensor 56 changes to OFF so that the tray 12 is
lifted, the tray 12 is stopped if a time limit lapses, even if the
trailing edge sheet surface sensor 56 does not change to ON. This
time limit is, for example, a time necessary for lifting the fourth
sheet to a position that is lower than that of the first sheet so
that at least the fourth sheet can be drawn up and conveyed as
illustrated in FIG. 10B.
In this way, in the stage of changing from the third sheet to the
fourth sheet, the tray 12 is stopped at the position where at least
the fourth sheet can be suctioned and conveyed, allowing for a
delayed raising of the rest of the sheets caused by compression of
the air cushions between the sheets. By the time the fourth sheet
has been conveyed away, the fifth sheet has equalised its air
cushion level and is ready to be conveyed, too. Thus, the influence
of the disturbance of the air cushions can be reduced. In other
words, the trailing edge sheet detection sensor 56 overrides to a
certain extent the leading edge sheet surface sensor 49.
As a further example, as illustrated in FIG. 10B, if the air
cushion is disturbed twice similarly to the case of FIG. 10A after
changing to the fifth sheet, the tray 12 is lifted in the first
disturbance similarly to the case of FIG. 10A. However, if the
signal from the trailing edge sheet surface sensor 56 changes from
OFF to ON, the tray 12 is stopped so that the lift amount of the
sheet surface is restricted. Thus, deviation of the level from the
original level of the sheet surface can be controlled to be R4 in
FIG. 10B. In addition, the tray 12 is not lifted in the second
disturbance because the tray 12 has reached an upper limit of the
lift amount in the first disturbance. As a result, the tray 12 is
controlled to be the position lower than the level when the feeding
was started by R3 in FIG. 10B. As a maximum level, the tray 12
could be moved to a position that is the same as when the feeding
was started.
In this way, unnecessary lifting of the tray 12 is prevented by
restricting the lift amount of the tray 12 after the trailing edge
sheet surface sensor 56 is turned OFF while the tray 12 is moving
upward. This OFF state of the trailing edge sheet surface sensor 56
is illustrated in FIG. 11.
This restriction of the lift amount is performed for each of the
sheets. In other words, the restriction of the lift amount is
temporarily cancelled when the object being controlled changes to
the next sheet. Thus, optimal control can be performed for each
sheet. Here, control of "one of sheets" may be defined as a time
period between start timings to rotate the suction conveyer belt
for feeding a first sheet and the next sheet. In addition, it may
also be defined as a time period between ON signals from the first
and the second sheet surface sensors 54 and 55 that are nearest to
a suction area obtained by feeding the sheet, or a time period
between start timings to activate a suction shutter solenoid SL
configured to rotate the suction shutter 37.
Next, the lifting and lowering control of the tray 12 will be
described with reference to a flowchart illustrated in FIG. 12.
When receiving a feed start signal, the control device 200 starts
preparation for feeding. First, rotation of the separation fan 31
is started, and air blowing is started, and hence sheets are lifted
by air cushions separating them. After that, if the first sheet
surface sensor 54 or the second sheet surface sensor 55 is not
turned on (NO in S31), the tray 12 is lifted and lowered (S32) as
required. When the first and the second sheet surface sensors 54
and 55 are turned on (YES in S31), feeding of the sheet is started
(S33).
Next, when the feeding of sheets is started, the uppermost sheet Sa
is drawn up and fed by the suction conveyer belt 21. After that,
when the sheet Sa is fed by the length of L2 (as illustrated in
FIG. 7) or more, the trailing edge separating portion 18 drops so
that a lower surface of the separation aid sheet 18E abuts a
surface of the next sheet Sb.
When the trailing edge separating portion 18 drops every time the
uppermost sheet Sa is fed, the trailing edge sheet surface
detection sensor flag 18G is also lowered along therewith. Soon
afterward, the trailing edge sheet surface sensor 56 no longer
detects the trailing edge sheet surface detection sensor flag 18G,
and hence the trailing edge sheet surface sensor 56 is turned off.
When the trailing edge sheet surface sensor 56 is turned off, the
tray 12 is lifted.
Next, it is determined whether or not the trailing edge sheet
surface sensor 56 is turned back on. If the trailing edge sheet
surface sensor 56 is still turned OFF, it is determined that the
level is still "too low", and the tray 12 is lifted.
Subsequently or alternatively, it is determined whether or not the
trailing edge sheet surface sensor 56 is turned on, or whether a
time limit has lapsed from the start of feeding sheets (S34). Here,
if the trailing edge sheet surface sensor 56 is not turned on, or
if the time limit has not lapsed from the start of feeding sheets
(NO in S34), the tray 12 continues to be lifted (S35).
After that, when the trailing edge sheet surface sensor 56 is
turned on, or when the time limit has lapsed from the start of
feeding sheets (YES in S34), the tray 12 is stopped (S36). When the
tray 12 is stopped at this timing, the sheet is lifted and is
stopped at the position where the first sheet can be drawn up and
conveyed as illustrated in FIG. 10B, for example. Thus, the sheet
can be fed. In addition, by stopping the action of lifting the tray
12 so as to restrict the total lift amount of the tray 12, it is
possible to prevent the tray 12 from being lifted too high even if
the trailing edge sheet surface sensor 56 repeats OFF and ON
frequently afterward.
When the feeding of the sheet is started after that, the position
control of the uppermost sheet is performed mainly based on the
trailing edge sheet surface sensor 56. Therefore, it is sufficient
for the sheet surface detection mechanism 49 for detecting the
sheet surface on the leading edge side to check whether or not the
uppermost sheet is lifted by the blown air in a predetermined
region.
Therefore, if the trailing edge sheet surface sensor 56 is turned
on, it is determined next whether or not the uppermost sheet
position is in the reference level (for the uppermost sheet to be
drawn up and conveyed by the suction conveyer belts 21) based on
the signal from the second sheet surface sensor 55. In other words,
if the second sheet surface sensor 55 is not turned on (NO in S37),
the tray 12 is lifted (S38) until the second sheet surface sensor
55 is turned on (YES in S37).
Further, if the sheet surface on the leading edge side is out of
the predetermined region despite the ON signal being obtained from
the trailing edge sheet surface sensor 56, i.e., if the second
sheet surface sensor 55 is turned off (NO in S37), the tray 12 is
lifted (S38). However, in this case too, the tray 12 (and therefore
the uppermost sheet) is already lifted to the level that enables
the trailing edge sheet surface sensor 56 output the ON signal, and
hence it does not take such a long time to lift the sheet that
throughput would be affected.
Next, when the second sheet surface sensor 55 is turned on (YES in
S37), the tray 12 is stopped (S39) and afterward the feeding of
sheets is started (S40). If N sheets are stacked (supported) on the
tray 12, the above-mentioned control is repeated until an N.sup.th
sheet is fed. When the N.sup.th sheet is fed (YES in S41), the
feeding operation is stopped.
In this way, in this embodiment, unnecessary lifting of the tray 12
is prevented by stopping the lifting of the tray 12 when the
trailing edge sheet surface sensor 56 is turned off as illustrated
in FIG. 11. Furthermore, by restricting the lift amount,
unnecessary lift of the tray 12 is not performed even if the
trailing edge sheet surface sensor 56 alternates between OFF and ON
frequently. Thus, an equilibrium state in air cushions between the
sheets can be sustained.
The time limit during which the tray 12 is lifted may be counted by
a timer, for example. It is desired that the time limit should be
set to a value for realizing the optimal equilibrium state of the
air cushions depending on a type, basic weight and a size of
sheets, and can be changed during the feeding process of the
sheets. In this embodiment, the time limit is set to 40 ms in the
case of thin sheets and to 100 ms in the case of thick sheets.
In addition, the lift amount of the tray 12 is restricted based on
timing counted by a timer or the like in the above description, but
the present invention is not limited to this. For instance, the
amount of rotation (number of pulses) of the tray lifting and
lowering drive motor M1 or a rotation angle may be monitored for
deciding the restriction. Further, the restriction of the lift
amount should be performed so that the throughput of sheets is not
lowered and the equilibrium state of the sheets floating on
respective air cushions is obtained. If it is difficult to achieve
both throughput and an equilibrium state, fine setting should be
performed in accordance with a type, basis weight, size, etc. of
the sheets.
Furthermore, the sheet feeding device 103 of the present invention
can be used for an image forming apparatus having an image forming
portion 102 and a sheet treating apparatus configured to treat the
sheets on which images are formed by the image forming portion
102.
While the present invention has been described with reference to
exemplary embodiments, it is to be understood that the invention is
not limited to the disclosed exemplary embodiments, but rather to
the scope of the following claims.
This application claims the benefit of Japanese Patent Application
No. 2009-020824, filed on Jan. 30, 2009, which is hereby
incorporated by reference herein in its entirety.
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